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This is a presentation from JSW Steel, one of the finalists at the 5th CII-GBC National …

This is a presentation from JSW Steel, one of the finalists at the 5th CII-GBC National
Award for Excellence in Water Management in 2008

The awards are in 2 categories, Within the Fence for work done on minimizing the organisations water footprint, and Beyond the Fence for work done in the community around the industry.

This presentation was in the "Within the Fence" category.

We thank CII and the respective companies for giving us permission to upload these presentations on the India Water Portal website for dissemination to a wider audience.

Published in Education , Technology , Business
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  • 1. TOTAL WATER MANAGEMENT 1
  • 2. JSW Steel – Group Companies SISCOL, Salem Tarapur JSW Steel, Vijayanagar – 4.0 mtpa. JSW Port, Goa VMPL, Iron Ore mining JPOCL JSW Captive power JSW Steel, Bellary 2
  • 3. JSW : Process – Raw materials to finished steel Non - coking coal Lum ore Iron ore Coking coal Fluxes Beneficiation Coke oven re mp Lump or Pelletization Sintering LCP HMDS Corex Blast furnace Converter LHF CCP HSM 3 HOT METAL STEEL
  • 4. JSW Steel Products Plates and Slabs HR Coils - Slabs - HR coils - Cold rolled coils - Pre coated - Galvanised - Bars & Rods - Structural etc. 4
  • 5. Industrial management system Entire Integrated Steel Operation certified BENEFITS DERIVED: DERIVED Consistent quality and quantity of water . Continuous improvements in quality. Lower Operational & Maintenance costs. Reliability of water for critical systems. 5
  • 6. Water from Tunga Bhadra Reservoir (32 MGD) Tunga Bhadra Reservoir Intake water pump house Raw water pond(6.5 Mm3 capacity) Clariflocculators(22.8 x 3 MGD) 6
  • 7. Water usage at JSW Steel Corex-1 4% Corex-2 3% BF-1 BF 1 3% Others 17% BF-2 5% SMS-1 8% HSM 3% CRM 2% Coke Ovens I & II 2% Power plants Pellet Plant & 38% Benification plant. 8% Sinter plant I 1% RMHS 1% FFPH 7 5%
  • 8. Water Usage in Integrated Steel Plants 1. Cooling of Metallurgical equipment (ICW) 2. Gas l i 2 G cleaning & Fume flushing F fl hi 3. Miscellaneous (Fire, drinking, gardening) 8
  • 9. Water usage – Company “Policy” 1. 1 Efficient use of available water Reduction of evaporation rate • Maximize use of alternate sources rain water & seepage. • Reduction of fresh water in closed circuits by higher COC. • Reverse osmosis plant for recovering good quality water. 2. Zero Discharge 2 Z Di h Cascading usage of water • Use of blow down of one process as make up water in other processes. • Equalization of final blow down water quality and its use in less critical applications. pp • Treated sewage for gardening. 9
  • 10. Efficient Use of water Fin-Fan heat exchanger Rain water harvesting Higher COC in Cooling towers Seepage water pumping 10
  • 11. Cascading use of water GCP 4.Consumptive Blow Down use 3. DCW Blow Down 1.DM/So 2. ICW Blow Down ft 11
  • 12. Water Cascading – Corex Plant Corex –DM Water Circuit Corex –ICW C ICW Corex –Slurry Water Circuit to PP Corex –GCP GCP Water Water Circuit Clarifier Blow down to Ore Beneficiation SLIME POND 12
  • 13. Waste water discharge – ‘zero’ GUARD POND -1 GUARD POND -2 Slag & Coke quenching Ore washing Best Practices-Green belt Greenery Development 13
  • 14. Water conservation – ‘total involvement’ Employee involvement Awareness A Water Help-Desk: Call 33457 Help Desk: Call-33457. Attend 15-20 calls per day. Action taken within 6 hours. 14
  • 15. Water – “Suggestion mela” 15
  • 16. Water - MIS Monitoring system g y Consumption: Flow meters at TOP of Shops:165 Nos. Daily readings at Production shops & Hourly reading readings at FFPHs. Quality: Hourly analysis of Raw water & Drinking water. Monthly M hl water analysis by external chemical laboratories. l i b l h i ll b i Reporting system Reports: Daily water consumption report (Enclosure3.xls). Monthly water report (Enclosure-5.xls) Monthly water cost (report) Review: Water consumption review in Daily HOD meeting. p y g Weekly water conservation meeting (Enclosure4.xls). DQEC meeting (MOM-May 2008.doc). 16
  • 17. Specific water consumption Year Annual Water consumption Specific fresh Production in tons water (April - 3 Source of Consumption Quantity Q antit (m ) March) Water Industrial Domestic Industrial 59,28,810 7,06,050 River 1875148 3.16 2004– 05 67,48,791 67 48 791 10,85,670 10 85 670 River Ri 2243509 3.01 3 01 2005 – 06 2006 – 07 85,51,293 11,38,490 River 2648359 3.23 2007 – 08 98,19,801 16,72,610 River 3159209 3.13 Year Industrial Township water consumption Ave rage Consumption Per capita Per capita employe es per No of persons m3 consumption Consumption day 2004-05 7,06,050 25,000 77 3,500 557 2005-06 10,85,670 28,000 106 4,000 487 2006-07 11,38,490 30,000 103 8,500 225 17 2007-08 16,72,610 35,000 130 18,700 124
  • 18. Water conservation projects A. Efficient use of water. Water Saving project implemented Payback Invest. Sl No Year Savings Period 3 Rs. Lakhs (Months) m Collection of seepage water from raw water pond a by constructing check dams and pump it back to 2004-2006 43.8 15 1 reservoir b Construction of guard pond-1 for 4 mtpa units 2005-06 1.8 6 12 c Construction of guard pond-2 for 7 mtpa units 2007-08 9 Construction of lake in Vidyanagar to harvest rain c 2005-06 40 water Improvement in the cycle of concentration by I t i th l f t ti b 2004-2008 d improving water treatment measures 10.5 194 45 (continuous) e RVDF project in RWTP 2005-2006 0.012 205 48 Collection of seepage water by Bore wells and f 2007-2008 1.28 2 4 utilization in iron making zone. Collection of seepage water along the RWP bund g 2006-2008 52.56 5 1 area and pumping it back to pond Utilization g ard Utili ation of guard pond water for VV Nagar ater f 2007-2008 8.76 15 5 township/Vidyanagar township/Plant horticulture/ 18
  • 19. B. Cascading use of Water. Invest. Year of Annual Water Made Payback Title of Water Saving Sl No Implement Savings Period project implemented ation 3 (Months) m Rs. Rs. Lakhs Lakhs Lakhs Utilization of blow down of a GCP water of Corex, BF 1&2 2007-2008 7.58 3.79 10 32 for make up in ore beneficiation plant Conversion of open circuit ID b fan cooling to closed circuit 2007-2008 2.73 13.65 15 14 cooling Utilization of blow down water c from CPP-2 for coke 2007-2008 6.57 32.85 6 3 quenching in to Coke oven-1,2 Collection of seepage water d from MSDS cable tunnel and 2007-2008 4.97 24.82 10 5 use in scale pit, of BOF. Recycling of blow down water R li f bl d t e 2007-2008 2.6 13 50 46 to slag quenching at BOF-CCP 19
  • 20. Water usage - analysis Cement Plant LCP Boilers RMHS Corex-1 utiltities Sinter plant I (25 TPH) Pellet Plant & Corex-2 HSM FFPH Benification BOC-1 plant. BF-1 CPP-2 JSWEL Corex Coke Ovens I & II FFPH. FFPH BF-2 CRM BF-2 FFPH CPP-1 JPOCL HSM Cokeoven SMS-1 FFPH Chart-1,4 MT Production units Chart-2, Fire fighting pump houses Chart-3, Power Plants Turbidity Chart Boilers utiltities Water to (80 TPH) Shankar Gudda colony IST steel plant 12 NTU WRM New batching SMS-2 VV Nagar plant T u r b i d i ty Coke Ovens III Vaddu village 7 NTU Crushing plant Water supplied to Township 7 MTPA Labour Hort. Colony/Drinking water For BF-3. Water from BF-3 Drinking water Sinter plant II RWP to Lake supplied to O NTU Water to plant. overhead tank Hour in Vidyanagar. Chart-4,7 MT Production units Chart-5,Miscellaneous units Chart-6 SPC 20
  • 21. Conservation projects - highlights A. A Application of Chemical in Raw water pond to reduce Evaporation . 1. Name of chemical : Ceta styrol Alcohol. 2. Supplier : Aqua Savia. 3. 3 Cost (Rs/kg) : 120 Rs/kg Rs/kg. 4. Application rate (kg/day) : 64 kg/day. 5. Cost of application per day : 8500 Rs/day. 6. Potential saving of water at 50% efficiency : 8000 m3/day. 7. Savings due to reduction. : Rs 20,000/day 21
  • 22. Evaloc is being mixed with water Solution is poured into a container Water Consum ption - March 2007 Water Consumption - March 2008 Evaporation loss 17% Evaporation loss 13% Others Others 5% 4% JSW 56% Ancillary units JSW Ancillary units 20% 57% 19% Drinking water Drinking water 4% 5% Total consumption = 2815.66 X 1000 m3 Total consumption = 2397.44 X 1000 m3 22
  • 23. 516 515 514 513 2004 512 2005 Raw Water Pond level 511 2006 510 2007 509 508 507 Jan F b M A M J Feb Mar Apr May J Jun J l A Jul Aug S Sep O t N D Oct Nov Dec Fig-3: Comparison of Evaporation Rates in cm 2.5 E vap o ratio n rate in cm 2 1.5 With & without 1 Evaloc application. 0.5 0 Jan Feb Mar Apr May June July Aug Sep Month Without Evaloc With Evaloc 23
  • 24. Conservation projects - highlights B. B Re use of seepage water & blow down water . Cable Tunnels constructed to collect seepage water . There are about 12 cable tunnel structures- VS-1, VS-2…VS-10. Entire seepage water is collected in VS-10(ventilation system). 24
  • 25. Cable Tunnel water is measured using Electromagnetic flow meter. g g Cable tunnel water is being pumped to consumer units. About 150 to 200 m3/day water is being saved. 25
  • 26. Conservation projects - highlights C. C Use of Guard pond water . Capacity of Each Guard p p y pond is 55,000 m3 . , There are two separate Guard ponds for 4 MT & 7 MT Stage. 26
  • 27. Guard pond pipeline network To 7MT ore Beneficiation plant pump house 7 MT Guard (1w+1s) pond II Storage Q= 300m3/hr cap. 55000m3 taken to 7MT GP Excess water To Beneficiation plant 150m3/hr VV Nagar o horticulture h ti lt s 30 m3/hr Plant 2. Horticulture 20 m3/hr 300 m3 Vidya Nagar 200 m3 township /Air port Horticulture Pump house (1w+1s) 2nd Boosting 50m3/hr Each cap. Q=250m3/hr cap 1st Boosting g station at station at t ti t H=70mtr Air strip RM Gate Guard pond I Storage cap. 25000 m3 27
  • 28. THANK YOU 28